Welding Process in roll forming machine


types of welding process in the roll forming machine:

Welding Process in roll forming machine: Welded profile applications increasing over the last 10 to 15 years, driven mainly by the automotive industry. 

though many welding technologies use on tube and pipe mills, three have come to the front: 

1.tungsten inert gas (TIG) such as gas tungsten arc welding (GTAW)

2. laser beam welding (LBW)

3.high-frequency induction (HFI) such as resistance seam welding (RSEW-I). 

These Welded technologies can divide into two groups, fusion welding and forge welding. GTAW and laser are fusion welding technologies and HFI is a forge welding technology.

Fusion Welding Process:

Fusion welding is a generic term for welding processes that rely on melting to join materials of similar compositions and melting points. 

GTAW generates an electric arc between a non-consumable tungsten electrode and the workpiece to produce the weld. The weld area is protected from atmospheric contamination by a shielding gas, either a single gas or a mixture of gases. GTAW sometimes call a “collapse” melting method, which implies that the weld puddle collapses back on itself as it solidifies. Because of this, the effect of gravity is a concern for two reasons. 

Laser beam welding (LBW): it provides a concentrated heat source, allowing for narrow, deep welds and relatively high welding rates. Like GTAW, LBW is a fusion process. The three main components in a laser system are the beam generator, the beam delivery system, and the focusing optics. 


Forge Welding Process:

Forge welding uses heat and a hammering or pressing process to make the joint.

HFI welding uses the same principles as induction heating. It is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, where eddy currents are generated within the metal and electrical resistance to this current flow leads to heating of the metal.


Welding Process in roll forming machine

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Pre-cut vs post-cut roll forming machine


How to choose your roll forming machine?



Roll forming is a continuous bending method in which a long tape of sheet steel is passed via rolls mounted on successive stands, each set executing only an incremental part of the bend, till the preferred cross-part profile is obtained. Roll forming is perfect for generating continuous-profile components with long lengths and in big quantities.

Pre-cut vs post-cut roll forming machine: There are two different types of roll forming machines, Pre-Cut roll forming machine, and Post Cut roll forming machine. There are advantages as well as disadvantages to both.

Advantages and disadvantages Pre-Cut roll forming machine 

Pre-cut advantages:

  • remove costly cut-off dies and their maintenance
  • Simple low-keeping pre-cut shear
  • Ability to hand-feed strips or sheets for low-volume production
  • In roofing and wall panel products, pre-cut avoids cut-off distortion 

Pre-cut disadvantages:

  • need more forming stations making the roll former and tooling more expensive
  • need more floor space
  • Difficult multi-bend parts 
  • Pre-cut may require intermediate guides, especially when running short pieces. 


Advantages and disadvantages post-Cut roll forming machine 


  • The production rate is higher with post-cut.
  • Better part control in terms of quality.
  • Better results for high-strength steels.
  • Lengths as short as 2 into 3 can produce.
  • Ability to provide punching/notching during the cut-off operation.


  • Expensive cut-off press and die.
  • Maintenance costs, especially for the cut-off die.
  • Distortion on product end.

Before investing in roll forming equipment, shops should select a manufacturer that can provide them with leading-edge designs and cost-effective solutions to satisfy any of their metal roll forming project needs. in fact, LOTOSFORMING is a leading roll forming industry in China for design roller and roll forming machines for other cooperators. We may build up the future altogether. Two basic types of roll forming systems are utilized: a pre-cut line and a post-cut line. certainly, a pre-cut line snips the incoming material to a specific length prior to roll forming. also, During post cut line operation, the roll-formed panel runs continuously after roll forming. you want to know Pre-cut vs post-cut roll forming machine please study this article.


Pre-cut vs post-cut roll forming machine

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Portable Roll forming Machine

What is a Portable Roll forming Machine? 

A portable roll forming machine operates very similarly full roll forming machine. small roll forming machine is this same roll forming idea just on a condensed level and takes everything a typical roll former does and packs it into a smaller size so it can be transported easily. Depending on the profile, most these machines have around 11 to 14 rolling stations on each side.

one of the important Types of Portable Roll forming Machinery is metal roofing roll forming machine growing popularity due to its durability, stability, Variety, colors, and so on. Portable metal roofing machines are in high request from both contractors and manufacturers. In addition to the panels produced for roofing structures, some machines can make the various metal wall and specialty panels.

Depending on the profile, most portable metal roofing roll forming machines have around 11 to 14 rolling stations on each side.


Advantages of Portable machine:

 one of the most important benefits is that these machines can be taken to any job site with or without a trailer attachment.and also having a roll forming machine cuts out the time spent waiting for panel deliveries.

Many portable forming machines offer the option to purchase more than one profile by changing the roller set. A Small size roll forming machine can produce continuously put panels up without stopping.


Disadvantages of Portable Rollforming

Training is vitally important when operating a roll former, and it helps to have a trained machine operator on staff, which means there are additional overhead costs to cover. If your mini roll forming machine is having an issue or out of adjustment should the job has stopped.



Portable Roll forming Machine

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All in one roll forming machine vs Cassette Type roll forming machine


All in one roll forming machine

All in one roll forming machine vs Cassette Type roll forming machine: today we are going to make some video to explain to you once the customer said I need that the roller roll forming machine or I need the cassette roll forming machine. sometimes a customer wants to combine their different profile into one single machine. there is some possible way, of course, and there but there is some choice one choice is a cassette and another choice is changing the roller.

but sometimes we will agree to change the roller for the customers for the sometimes we don’t. it depends on their profile what kind of profile the customer wanna make. the other one also depends on the rollers if we complicate one or it’s an easy one to change.
Different roll forming machines can use to make different roll forming products, such as double roll forming machines and all-in-one roll forming machines, etc. However, cassette type roll forming machines always come to people’s minds in some times.

 Roll forming machines

suppose there is one new machine and we want to insulate it that the rollers. here we are some measure it’s not a high technology way but it’s, of course, there are some traditional and useful the way. we make some liner to make sure the roller central will be in the same line.  in the first step, workers will put their rollers together with the shaft.
and after installation the rollers the shaft end the bearing broke and we had the problem also we have the up layer(up roller) and the down layer(down roller). The second step is how we adjust the shape to qualify.
An all-in-one roll forming machine usually consists of one decoiler, one roll former,  one cutter, one control box, one oil pump, and one set of run-out tables, so it would save working space.

How to adjust the rollers of the roll forming machine


 Cassette Type roll forming machine

All in one roll forming machine vs Cassette Type roll forming machine: The Cassette Type roll forming machine has several sets of individual cassettes tools, consisting of different rolling tools, shafts and operation stand. cassette type roll forming machine design to produce a variety of cold-formed profile by quickly changing different cassettes and sharing the same machine base.
cassette type roll forming machine is popular because they can assemble different cassettes on the main machine base to roll form different metal products.

Variations type roll forming stand

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Adjusting the gap between rollers



How to adjust the rollers of the roll forming machine?

Adjusting the gap between rollers, Roll Forming Machines are flexible and continuous processes. It has been proven several times that the roll forming machine does roll forming tasks which even seemingly impossible. though it may take a longer time and much more money. it also showed that plans to roll form simple shapes can create disastrous results. If the designer doesn’t follow the basic rules of roll forming.
Rollers are one of the main components of the roll forming machine. In practical terms, rollers manufacturing must be hardly precise. The deviations of roundness or eccentricities of a very low order will have great implications in part quality.  And the surface quality must be extremely high due to contact and lubrication issues. As usual, rollers are split into several sections for ease of manufacturing. In fact, there are instances where this is the only possibility and also allows for easier installation.

Adjusting the gap between rollers

in this page you can learn all thing about:
  • Roll Forming Machine Rollers
  • how to lose shaft and move space sleeve in roll forming machine
  • How to adjust the rollers of the roll forming machine
  • How to Change Spacer Multi-Profile of the roll forming machine
  • Spacer change for multi-profile roll forming machine
  • Change size by change spacer for roll forming machine
  • How to Change Roller Spacers of Roll Forming Machine for Different Profile 
  • adjusting the gap between rollers roll forming machine
  • How to adjust the roller mold width

Roll Forming Machine Rollers

Between the rollers are spacers, which will reduce the cost of the mill. And easy to adjust to produce a different desired profile with split spacers. After confirming the total length of the rollers. It requires less expensive spacers to fill the space between the rollers. The spacers usually produce by seamless pipes.
The max and min length of the spacers limit by the space of the rollers. and length tolerance is very important. inner diameter of the spacers should be a bit larger than the outer diameter of the shafts. most frequently used spacers make out of one piece, and some times we also use Split Spacers. The split spacers can reduce the roller change over time of various width profiles. Instead of removing the nuts from the end of the shaft, pulling out the roll forming stands, rollers, and also the spacers.


How to adjust the rollers of the roll forming machine

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How to adjust the roller gap


Adjust the gap Between the up roller and down roller:

Many roll-to-roll forming processes usually use a series of hard pressure rollers, to deliver smooth, high-quality products. Ensuring a consistent material thickness depends on the ability to monitor, and hold a precise gap between rollers. 
Establishing a roller gap and checking for parallelism across roller width can be a slow and cumbersome procedure. Manual measurement requires multiple sized feeler gauges.


If the adjustment knobs turn when you receive the mill, then the screws may have loosened during shipment, and you need to check the gap setting. when you have brewed using some grain that you crushed with the factory gap setting, you’re ready to adjust the gap and turn up the efficiency of your factory. 
To adjust the gap, loosen the screws so the knobs can turn. Use a feeler gauge to measure and set the gap. Slide the feeler gauge shims into the gap on one end of the rollers. Tighten the knobs so the feeler gauge is tight in the gap. Repeat on the other end of the roller to be sure they are parallel. Tighten the screws on the adjustment knobs. 
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Roll Forming Machine Operator

Metal Roll Forming Machine Operator Jobs


The Roll Forming Machine Operator tends fabricating machines such as rolls, presses, forming machines, spinning machines. The roll forming Machine Operator will be responsible for operating the equipment.

1.      Feed materials into inline forming machines and perform roll changes as necessary. Observe rollforming machine operation to detect workpiece defects or roll forming machine malfunction.

2.       Set up all work centers within the department in accordance with established procedures and make necessary adjustments to achieve a part that meets all specifications.

3.       Set up duties include but are not limited to; changing molds and dies out of machines, properly securing and connecting utilities to tooling, and installing the proper program into the machine.

4.       Feed materials into inline forming machines and perform roll changes as necessary.

5.       Remove scrap materials from the machine and dispose of per procedures.

6.       Observe machine operation to detect workpiece defects or machine malfunction and report any findings to the Supervisor.

7.       Monitor and measure specific characteristics of the product using measuring equipment.

8.       Inspect quality of finished product and report any quality issues to Setup/Lead Person or Shift Supervisor.


 Roll forming machine Jobs

9.       Input accurate daily production information in the computer shop floor data collection system.

10.   Assist roll forming operators with job functions such as relieving machinery for scheduled breaks, moving product and scrap to and from work stations, and assisting material handler with moving raw materials to and from work stations.

11.   Properly complete all necessary paperwork and forms needed for setup or production.

12.   Recommend measures to improve production methods, equipment performance, and quality of the product.

13.   Perform all work procedures according to established Quality Management & Environmental Management Systems.

14.   Perform job responsibilities and tasks in compliance with Company policies, procedures and safety, and environmental regulations.




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Manual Decoiler Machine


Decoiler meaning:


A material handling machine located at the beginning of a production line. decoiler used to hold and safely pay off or uncoil the steel strip. Coiler controls the speed and direction of the strip of metal and is sent to the line for processing, such as slitting or tube mill entry also roll forming entry. Decoiling is the action of unwinding a parent coil, making it flat and cutting it into sheets.


Manual Decoiler Machine


Decoiler machine design

actually, there is a sensor between decoiler and roll forming machine. If the coil is tight, the sensor will let the uncoiler go forward. If the coil is loose, the sensor will let the uncoiler stop. in fact, LOTOS specializes in providing custom-built Manual Decoiler to our customers. De-Coiler offered by us finds application as an accessory machine that is used as support for expanded metal mesh machine.

Decoiling Machine

decoiler or uncoiler use in all roll forming machine such as:



A manual decoiler is cheaper , while a semi-auto decoiler or an auto decoiler may cost Multiply. A manual decoiler consists of welded steel and two bearings; a semi-auto decoiler requires a motor with reducer, and an auto decoiler has a motor, hydraulic system, frequency inver, and control unit. 

We produce all kind of decoiler types such as Automatic Sheet Uncoiler Machine, Automatic motorized Uncoiler Machine, Automatic Decoiling Machine, Automatic Uncoiler, Automatic Uncoiler Machine:

Double Head Mechanical Decoilers

Horizontal Mechanical Uncoilers

Mechanical Uncoilers

Motorized Mechanical Decoilers


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Roll Forming Operation Manual


How to adjust a roll former ??

LOTOSFORMING guides and explains many of the common issues encountered in the roll forming process and roll forming operation manual, all factors that contribute to possible problems such as material, design, and manufacture.

roll forming operation manual is a process that developed by gradually bending the metal through a series of roll stands, or passes. Each stand must produce the appropriate amount of deformation for which it was designed. when roll-forming problems occur. it is important to examine each stage of the process and not merely the stand at which the problem initially appears. The goal of a roll forming operation achieves when there is uniform metal deformation throughout the line. Roll forming operation manual design to be reasonable during the operation. If run “popping” throughout the operation, the operation needs to be investigated.

Two basic types of roll forming systems utilize a pre-cut line and a post-cut line. A pre-cut line snips the incoming material to a specific length prior to roll forming operation manual. During post cut line operation, the roll-formed panel runs continuously and shear to the required length after roll forming.


roll former



Roll forming operation :


One of the main parameters that define the success of a roll forming operation is the character of the material. for design the optimal process, the designer should provide material information to use prior to the tooling designing such as material mechanical property ranges, gauge tolerances and shape tolerances, different metallic coatings.



Mill alignment is critical. forming rolls and their components must align with each other both horizontally and vertically. The rolls must align both side-to-side and pass-to-pass. Forming material with the gauge either lighter or heavier than that for which the tooling is designed can result in problems. Using material thinner than the designed gauge can lead to finish radii greater than the intended design. This is usually offset by over-tightening the rolls, which causes a decline in tool life.

 Processing heavier gauge material than intended can also lead to larger radii than designed. When running thicker material, the tooling will make contact on the side of the tool radii leaving no center contact with the tooling. Since the material is not in proper contact with the tooling, gap differences from side to side become more critical. Small side-to-side roll gap differences can result in a twist, bow or sweep problems.

Roll forming components


setup by the roll tooling manufacturer, feeler, or wire gauges is most often used to set the gaps on roll-forming stands. This should ideally be done each time the metal being utilized changes significantly in gauge. Operators must be sure to periodically check for tooling wear or machine wear.

Each stand consists of top and bottom rolls designed to provide the necessary part dimensions. position of the top roll can be adjusted via screws to change the gap between rolls, thereby changing the forming pressure applied to the metal at each stand. The final roll gap adjustment on each stand should always be down to compensate for the gear and bearing tolerances inherent to each stand.



Cutoff dies or shears are available in many types and variations. The most common types utilized for roll forming machines are the “slugless crop die” and the “flying shear”, or “cutoff die”.cutoff operation accurately cuts the part to the desired length in a manner that is essential to the continuous operation of the line. Slugless crop dies generally have a short stroke length, possess contoured blades, and rapidly cut-off the finished part. Since the cut-off action is extremely fast, and accurate cut can normally be performed without interruption to the continuous operation of the line. Proper set-up in this type of operation is critical.


Roll forming machine design

Line speeds, die speeds, and die clearances must closely establish and monitor to prevent blade drag. This condition can result in panel buckling. Removal of the buckled panel from the line is time-consuming and may result in damage to the cutoff die, or in extreme cases, to the roll tooling. Even if the part does not buckle to the point that it jams the line, improperly timed cutting can cause problems upstream in the roll former.

Momentary interruptions in the later roll-forming stand, while the initial stands are still driving the material, can result in a wide variety of problems and/or imperfections. Minor buckling in the intermediate stands can result in oil canning type imperfections as well as other twist or dimensional issues in the finished panel. If the line is set-up with extremely loose tooling clearances. the effect of momentary line interruption from the cutoff operation may be seen all the way to the uncoiler. In this instance, the alignment of the entire line becomes integral to the cut-off operation. For example, if the uncoiler is out of alignment, the momentary line interruption could pull the material in a skewed manner from the uncoiler and potentially cause oil canning, twist or sweep problems.

Roll forming stands

A flying shear, or cut-off die, may require an increase in the line speed or panel height configuration. This allows the shear or die to attain the speed of the line prior to the cutoff operation. The timing of the shear is critical in this operation. Momentary interruptions in the latter roll-forming stands, as described above, will generally be larger in magnitude and more serious in nature as the speed of the cut-off operation increases. blade or die should always cut to an approved part. Improperly design/machine tools must avoid because they result in tight clearances, induce blade drag, tool drag, or lose clearances, which result in burrs on the finished panel.


roll forming machine price

roll forming machine price


Roll forming machine configuration :

With a working knowledge of the roll forming machine configuration and the roll former setup procedures, the root cause of many problems can determine at the plant level. Generally, the most important factor to keep in mind is that roll-forming issues must approach from a systematic point of view. That is, everything must consider from the incoming material properties, lubrication, roll former setup, uncoiler, and cut-off methods to the inspection details of the finished product. All or any of these factors can impact the acceptance of the finished part.


 adjusting the roll forming machine :

What are the Tool Gap Settings?

Gaps should initially be set at the material gauge with final adjustments made to achieve the desired final dimensions.


Does It Hold Dimension?

Ensure that the material within the order width and property tolerances. Check the gaps in the overbend stands for proper gauging.

Where Does the Imperfection Appear?

Inspect and check the tooling and gap settings where the imperfection occurs and in the stands upstream. Adjust to appropriate settings.


Are There Tight or Loose Areas on the Finished Panel Radii?

These imperfections typically denote improper tooling adjustment or worn tooling or bearings. Ensure that the tooling has proper gap settings. Inspect the tooling for worn areas. Inspect the line during operation for bearings with excessive movement. Occasionally, a worn bearing will make noise during operation. If bearing wears isolate and is consistently in one stand, it would be prudent to inspect the tooling in the entire line for alignment, wear and proper gap settings.


Roll Forming Systems :

Does the Tooling Run Eccentrically or Wander with Respect to Other Stands?

This is an indication of bent shafts, worn bearings, worn or misaligned tooling. If the tooling visually wanders from side to side, either the bearings are worn or the shaft locknut has come loose, or a shim has worn or fallen out. When the tooling is running in an elliptical pattern (egg shape, or up and down) the shaft itself may be bent. This will require checking the shaft for run-out with a dial indicator for the amount of movement.

This normally indicates dry material, tight clearances, or improper tooling setup. Tooling stands where material slivers and/or debris accumulate should closely monitor, as this can lead to premature wear and finish panel imperfections. Material run with insufficient lubrication (dry areas) will run with increased friction in these areas during forming. This can cause the material to scrape during the roll-forming process, especially on the panel edges. In some cases, running dry material can raise the temperature of the tooling sufficiently to reduce the die clearances from heat expansion.

Tooling that gape to less than the material being formed, or tooling that is out of alignment from stand to stand can also cause this problem. Although it is sometimes not possible to prevent material debris accumulation on some stands. tooling should gape and check for alignment frequently.

Portable roll forming machine

Does the Material Track Properly into and from the Line?

Material that has differential lubrication edge-to-edge, the material with significantly different thickness edge-to-edge or tooling that is out of adjustment can cause tracking issues.


Does the Imperfection Appear at One Stand?

If this is the case, ensure the tooling gape properly at both the imperfection stand and also at the stands prior to where the imperfection occurs.


Does the Cut-Off Operation Run Transparent to the Line?

Drag or an out-of-time cut-off operation can induce a variety of imperfections or problems. In a post-forming cut-off process, the cut-off should not alter the continuous forming of the panel. Dull cut-off dies or knives can impart sufficient drag in the cut-off operation so that the formed panel actually begins to buckle in the cut-off operation. A similar condition is possible if a flying shear is out-of-time with the speed of the forming operation. Both of these conditions should address when they first appear, as permitting them to continue will eventually cause the panel to buckle in the line prior to the cut-off.


Roll forming machine for sale

Successful roll-forming relies on a combination of factors, including material properties, tooling set-up, and roll former operation. As problems arise, it may be difficult to ascertain which factor is negatively impacting the finished panel to the point of rejection. This is why it is imperative to view the roll-forming process from a systematic point of view. With this approach, it is possible to determine the root cause of the problem and take the appropriate corrective course of action.

roll forming machine for sale

roll forming machine for sale

You can find all the information about the following :

  1. Shaft and roller design

  2. installation for roll forming machine
  3. Complete video for roll forming down roller adjustment
  4. How to fix roller position on the roll forming machine
  5. Advanced roll forming
  6. Custom Roll Forming Process
  7. Roller Die
  8. roll forming roller material
  9. How to adjust roller on the roll forming machine
  10. roll forming roller design
  11. Complete video for roll forming the base setting
  12. roll forming basics
  13. How to adjust the roll forming machine
  14. roll forming process


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Roll-up Shutter Door

In the previous generations, most shops and garages were closed by handmade steel bar doors or corrugated sheet doors. After ROLL FORMING MACHINE comes up to produce door shutter, all doors are changed to shutter slats. It has so many advantages from old-style doors. That here, we explain some good point of Roll-up Shutter Door.

China Supplier Roller Shutter Door Roll Forming Machine

Roller Shutter Door

Shutter Door Repairs

  • shutter door producing is more fast and easy by shutter roll forming machine; with any rolling shutter door details, shutter roll forming machine can produce within 10 minutes.
  • Installation for metal shutter door is faster and easy than old doors. Shutter and shutter joined together, and make various height for any Garage Shutter Doors.
  • For using: open and closed doors, it’s so fast and convinces with roll-up shutter door with tubular motor;
  • Shutter Door Repairs just check the shutter one by one, only need to change the damaged shutter, not necessary for whole doors replacement.

  • Not limited with listed advantages, but more benefit will be discovered during daily usage of ROLLING SHUTTER DOORS.


Rolling Shutter Slats Roll Forming Machine

Rolling Shutter Slats


Different types of Door Shutters:

In LOTOSFORMING MANUFACTURE, we mostly do door shutter design based on customer’s requirement, and shutter joint safety standard. But here, we wanna explain some global well-recognized door shutters:

  • Perforated Roller Shutter: it’s applied punch before forming step;
  • PolyurethaneFoamed Door Shutter: it’s applied PU Foam inside of shutter, it’s good for Fire-Proof and Sound-Proof. Less noise during rolling up and down;
  • Single Layer Rolling Shutter Door: in different door shutter design, such as shutter width and shutter section drawing.
Window shutter roll forming machine

Window shutter


Roller Shutter Doors producing:

All steel roller shutter is produced by Shutter Door Roll Forming Machine. In LOTOSFORMING, we use several types of rolling shutter machines based on shutter drawing.

  • Chain Transmission Rolling Shutter Machine;
  • Gearbox Transmission PU FOAMED Door Shutter Roll Forming Machine.

Up to Door Shutter Design, LOTOSFORMING engineers design proper rollers and forming steps according to shutter design.


roll forming machine door shutter

door shutter


Roller Shutter Doors Manufactures

should have a long history on design and produce rolling shutter machines to satisfy the standard requirement for final Foamed Shutters.

LOTOSFORMING ROLL FORMING Machine Manufacture has more than 50-year remarkable experience on Rolling Shutter Making Machine

Shutter Patti Machine is including decoiler, forming stations, hydraulic cutting unit, and PLC control system, and finished output table.

For Rolling Shutter Raw Material, different material could be applied, such as aluminum, galvanized(GI), color coated steel (PPGI) and PVC coated steel, and stainless steel (S.S) and so on.


Mostly, Shutter Door Roll Forming Machine, LOTOSFORMING install lubrication oil feeding device on the roll forming machine input, to mop the material with rollers to protect shutters material coated surface.

For any further question and inquiry, for shutter roll forming machine design and proposal, you may feel free to contract with LOTOSFORMING Roll Forming Machine Manufacturer.


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